Linear propulsion system

ABSTRACT

A linear propulsion machine and system ( 10 ) is disclosed that includes a stator ( 30 ) having a plurality of teeth ( 34 ) and a mover ( 32 ) moveable in a linear direction along the stator ( 30 ). The mover may include a plurality of spaced apart ferromagnetic strata ( 40 ), a plurality of slots ( 42 ), a plurality of wire coils ( 44 ), and a plurality of magnet layers ( 46 ). Each of the slots ( 42 ) may be adjacent to at least one of the strata ( 40 ). Each coil ( 44 ) may be disposed in a slot ( 42 ). Each magnet layer ( 46 ) may be sandwiched between strata ( 40 ) and disposed inside one of the plurality of coils ( 44 ). Each coil ( 44 ) is disposed perpendicularly to the direction of magnetic flux of the magnet layer ( 46 ) around which the coil ( 44 ) is wound. In an embodiment, the teeth ( 34 ) or the magnet layer ( 46 ) may be disposed at an angle.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No.15/100,740 filed Jun. 1, 2016, which is a U.S. national stage of PatentApplication no. PCT/US2013/073303 filed Dec. 5, 2013, all of which areincorporated herein by reference in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure generally relates to linear propulsion system,and, in particular, relates to self-propelled elevator systems.

BACKGROUND OF THE DISCLOSURE

Self-propelled elevator systems, also referred to as ropeless elevatorsystems are envisioned as useful in various applications (i.e., highrise buildings) where the mass of the ropes for a roped system isawkward and there is a desire for multiple elevator cars in a singlehoistway. There exist self-propelled elevator systems in which a firsthoistway is designated for upward traveling elevator cars and a secondhoistway is designated for downward traveling elevator cars. A transferstation at each end of the hoistway is used to move cars horizontallybetween the first hoistway and the second hoistway.

A cost effective elevator system is desired.

SUMMARY OF THE DISCLOSURE

In accordance with one aspect of the disclosure, a linear propulsionmachine is disclosed. The linear propulsion machine may comprise a firststator and a first mover. The stator may include a plurality of teeth.The first mover may be adjacent to the first stator and moveable in alinear direction along the first stator. The mover may include aplurality of spaced apart ferromagnetic strata, a plurality of slots,each of the slots adjacent to at least one of the strata, a plurality ofwire coils, and a plurality of magnet layers. Each magnet layer may besandwiched between two of the strata and disposed inside one of theplurality of coils. Each coil may be disposed in at least one slot, andthe coils may have an activated state and a deactivated state. Each coilmay be disposed substantially perpendicularly to the direction ofmagnetic flux of the permanent magnet layer around which the coil iswound. The teeth or the permanent magnet layer may be disposed at anangle from a plane substantially perpendicular to the direction ofthrust on the first mover generated by the interaction of the firstmover with the first stator.

In a refinement, the plurality of slots may be a multiple of a number ofphases of the linear propulsion machine.

In another refinement, each of the plurality of teeth may include askewed side surface.

In yet another refinement, each of the plurality of teeth has a toothwidth and a distance across the slot between two strata is a slot width,wherein the slot width is about the same as the tooth width.

In another refinement, each of the strata may include a skewed strataside surface.

In another refinement, the linear propulsion machine may further includea second stator. The first mover may be disposed between the first andsecond stators.

In another refinement, the linear propulsion machine may further includea second mover moveable in a linear direction along the first stator.The first stator may be disposed between the first and second movers. Ina further refinement, the magnet layers of each of the first and secondmovers may be angled in relation to the first stator. In anotherrefinement, the linear propulsion machine may further include a thirdand fourth mover moveable in a linear direction along the first stator.The first stator may be disposed between the third and forth movers andthe third and fourth movers may be offset from the first and secondmovers.

In accordance with another aspect of the disclosure, another linearpropulsion machine is disclosed. The linear propulsion machine maycomprise a first stator, and a first mover. The stator may include aplurality of teeth, each of the teeth having a magnetic pole. The firstmover may be adjacent to the first stator and moveable in a lineardirection along the first stator. The teeth of the first stator and thefirst mover may define a gap. The mover may include a plurality ofspaced apart ferromagnetic strata, a plurality of slots, a plurality ofwire coils, and a plurality of permanent magnet layers.

Each permanent magnet layer may be sandwiched between two of the strataand disposed inside one of the plurality of coils. Each of the slots maybe adjacent to at least one of the strata. Each coil may be disposed inat least one slot. The coils may have an activated state and adeactivated state. The plurality of permanent magnet layers may bemounted on the mover to have reversed polarities with consecutivepermanent magnet layers in a longitudinal direction along the mover.Each coil may be disposed substantially perpendicularly to the directionof magnetic flux of the permanent magnet layer around which the coil iswound. The teeth or the permanent magnet layer may be disposed at anangle in the range of about −60° to about 60° from a plane substantiallyperpendicular to the direction of thrust on the first mover generated bythe interaction of the first mover with the first stator.

In a refinement, each permanent magnet layer may have a trapezoidalshape.

In another refinement, each permanent magnet layer may be comprised offirst and second permanent magnets. The first permanent magnet may bedisposed between the stator and the second magnet. The first permanentmagnet may be a bonded magnet.

In accordance with yet another aspect of the disclosure, an elevatorsystem is disclosed. The elevator system may comprise a hoistway, a cardisposed within the hoistway, and a linear motor. The linear motor mayinclude a first stator disposed in the hoistway and including aplurality of teeth, and a first mover mounted on the car and adjacent tothe stator. Each of the teeth of the first stator may be a magneticpole. The first stator may be made of laminated ferromagnetic material.The first mover may be moveable in a linear direction along the firststator. The mover may include a plurality of spaced apart strata made oflaminated ferromagnetic material, a plurality of slots, a plurality ofpermanent magnet layers, and a plurality of wire coils. Each of theslots may be adjacent to at least one of the strata. Each permanentmagnet layer may be sandwiched between two of the strata. Each permanentmagnet layer may be comprised of a first magnet and a second magnet. Thefirst magnet may be disposed between the second magnet and the stator.The first magnet may be a bonded magnet. The second magnet may be asintered magnet. The coils may have an activated state and a deactivatedstate. Each coil may be disposed in at least one slot and wound aroundone of the permanent magnets. Each coil may be disposed substantiallyperpendicularly to the direction of magnetic flux of the permanentmagnet around which the coil is wound. The linear motor may be apolyphase motor. A first group of the plurality of wire coils may carryalternating current with a different phase than a second group of theplurality of wire coils.

In a refinement, the teeth may be disposed at an angle in the range ofabout —60° to about 60° from a plane perpendicular to the direction ofthrust on the first mover generated by the interaction of the firstmover with the first stator.

In another refinement, the permanent magnet layers may be disposed at anangle in the range of about −60° to about 60° from a plane perpendicularto the direction of thrust on the first mover generated by theinteraction of the first mover with the first stator.

In another refinement, the plurality of teeth may be one greater thanthe plurality of slots.

In another refinement, the elevator system may further include a secondstator. The first mover may be disposed between the first and secondstators.

In another refinement, the elevator system may further include a secondmover mounted to the car and moveable in a linear direction along thefirst stator. The first stator may be disposed between the first andsecond movers. In a further refinement, the teeth of the first andsecond movers may be disposed at an angle in the range of about −60° toabout 60° from a plane perpendicular to the direction of thrust on thefirst mover generated by the interaction of the first mover with thefirst stator.

In another refinement, the elevator system may further include a thirdand fourth mover mounted to the car and moveable in a linear directionalong the first stator. The first stator may be disposed between thethird and forth movers and the third and fourth movers may be offsetfrom the first and second movers. The offset may be a distance in therange of more than zero to about one per unit stator channel pitch.

These and other aspects of this disclosure will become more readilyapparent upon reading the following detailed description when taken inconjunction with the accompanying drawings.

FIG. 1 is an embodiment of an exemplary elevator system;

FIG. 2 is an another embodiment of an exemplary elevator system;

FIG. 3 is a perspective view of one exemplary embodiment of a linearmotor for an elevator system constructed in accordance with theteachings of this disclosure;

FIG. 4 is a perspective view of another exemplary embodiment of a linearmotor;

FIG. 5 is a schematic front view of the linear motor of FIG. 4 with thelines of magnetic flux illustrated;

FIG. 6 is a perspective view of another exemplary embodiment of a linearmotor;

FIG. 7 is a schematic front view of the linear motor of FIG. 6 with thelines of magnetic flux illustrated;

FIG. 8 is an alternative embodiment with two linear motors mounted on anexemplary car;

FIG. 9 is a graph of the average thrust force and percentage thrustforce ripple as a function of offset between the two linear motors ofFIG. 8;

FIG. 10 is a graph of the thrust force as a function of linear motoroffset for the two linear motors of FIG. 8;

FIG. 11 is a front view of the exemplary linear motor of FIG. 3 with thestator teeth angled;

FIG. 12 is a front view of the exemplary linear motor of FIG. 3 with themagnet layers of the mover angled;

FIG. 13 is an enlarged schematic of an exemplary magnet layer of amover;

FIG. 14 is a schematic of another exemplary embodiment of a magnetlayer;

FIG. 15 is a schematic showing an enlarged view of a portion of anexemplary mover; and

FIG. 16 is a schematic showing an enlarged view of a portion of anexemplary stator and tooth.

While the present disclosure is susceptible to various modifications andalternative constructions, certain illustrative embodiments thereof havebeen shown in the drawings and will be described below in detail. Itshould be understood, however, that there is no intention to be limitedto the specific forms disclosed, but on the contrary, the intention isto cover all modifications, alternative constructions, and equivalentsfalling within the spirit and scope of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

The linear propulsion system 10 disclosed herein may be utilized inapplications that require movement of a vehicle along a track. Forexample, the linear propulsion system may be utilized for elevators,trains, roller coasters, or the like.

To facilitate the understanding of this disclosure, the linearpropulsion system will be described as utilized in a linear motorpropelled elevator system. It is to be understood that the linearpropulsion system is not intended to be limited to elevatorapplications. The elevator application described herein is an exemplaryembodiment described in order to facilitate understanding of thedisclosed propulsion system.

Referring now to FIG. 1, a propulsion system 10 is shown in schematicfashion. The propulsion system is an exemplary elevator system thatutilizes one or more linear motors. As shown in FIG. 1, the elevatorsystem 10 comprises a hoistway 18 that includes a first hoistway portion12 and a second hoistway portion 16. The first and second hoistwayportions 12, 16 may each be disposed vertically within a multi-storybuilding. The first and second hoistway portions 12, 16 may be dedicatedto directional travel. In some embodiments, the first and secondhoistway portions 12, 16 may be part of a single open hoistway 18. Inother embodiments, the first and second hoistway portions 12, 16 may bepart of a divided hoistway 18 that has a wall or other divider betweenthe first and second hoistway portions 12, 16. The hoistway 18 is notlimited to two hoistway portions. In some embodiments, the hoistway 18may include more than two hoistway portions disposed vertically within amulti-story building.

In the embodiment illustrated in FIG. 1, elevator cars 14 may travelupward in the first hoistway portion 12. Elevator cars 14 may traveldownward in the second hoistway portion 16. Elevator system 10transports elevator cars 14 from a first floor to a top floor in thefirst hoistway 12 and transports elevator cars 14 from the top floor tothe first floor in the second hoistway 16. Above the top floor is anupper transfer station 20 where elevator cars 14 from the first hoistway12 are moved to the second hoistway 16. It is understood that the uppertransfer station 20 may be located at the top floor, rather than abovethe top floor. Below the first floor is a lower transfer station 22where elevator cars 14 from the second hoistway 16 are moved to thefirst hoistway 12. It is understood that lower transfer station 22 maybe located at the first floor, rather than below the first floor.Although not shown in FIG. 1, elevator cars 14 may stop at intermediatefloors to allow ingress to and egress from an elevator car 14.

FIG. 2 depicts another exemplary embodiment of the elevator system 10.In this embodiment, the elevator system 10 includes an intermediatetransfer station 24 located between the first floor and the top floorwhere the elevator car 14 may be moved from the first hoistway portion12 to the second hoistway portion 16 and vice versa. Although a singleintermediate transfer station 24 is shown, it is understood that morethan one intermediate transfer station 24 may be used. Such anintermediate transfer may be utilized to accommodate elevator calls. Forexample, one or more passengers may be waiting for a downward travelingcar 14 at a landing on a floor. If no cars 14 are available, an elevatorcar 14 may be moved from the first hoistway portion 12 to the secondhoistway portion 16 at intermediate transfer station 24 and then movedto the appropriate floor to allow the passenger(s) to board. It is notedthat elevator cars may be empty prior to transferring from one hoistwayto another at any of the upper transfer station 20, lower transferstation 22, or intermediate transfer station 24. The elevator system 10includes one or more stators 30 disposed within each hoistway portion12, 16. The stator 30 generally extends the length of the hoistwayportion 12, 16 and may be mounted on a support frame, a wall of thehoistway 18, or the like. The elevator system 10 further includes one ormore movers mounted to each car 14.

Turning now to FIG. 3, therein is shown one exemplary arrangement of afirst stator 30 disposed within a hoistway portion 12, 16 and a firstmover 32 mounted to a car 14. The stator 30 may include a plurality ofteeth 34 and is made of ferromagnetic material. For example, in oneembodiment, the stator 30 may be made of silicone steel, or the like. Insome embodiments, the stator 30 may also be a laminated material. Inbetween each of the teeth 34 is a channel 35. Typically, the quantity ofchannels 35 is an even number.

Each of the plurality of teeth 34 has a tooth width W. Further, each ofthe teeth 34 of the stator 30, when adjacent to the mover 32, may be amagnetic pole M. For example, in FIG. 3 the stator 30 has eight (8)poles Mover the length of the first mover 32. The number of poles M ofthe stator is different than the number of slots 42 of the mover (slots42 are discussed in more detail later) over the length of the mover. Forexample, the number of poles M may be one (1) greater or less than thenumber of slots 42, two (2) greater or less than the number of slots 42,three (3) greater or less than the number of slots 42, etc. In general,the closer the number of slots 42 of the mover is to the number of polesM of the stator (over the length of the mover), the better theperformance of the linear motor.

The mover 32 is adjacent to the stator 30 and is moveable in a lineardirection along the stator 30. The teeth 34 of the stator 30 and themover 32 define a gap 38. In some embodiments, the gap 38 may be an airgap. The mover 32 may include a plurality of spaced apart strata 40, aplurality of slots 42, a plurality of wire coils 44, and a plurality ofpermanent magnet layers 46.

Each strata 40 may each be made of ferromagnetic material. In someembodiments, each strata 40 may be made of laminated ferromagneticmaterial. In some embodiments, each strata 40 may be generally L-shapedsuch that two consecutive strata may form a U-shape pair. The strata 40are not limited to this shape and may be other shapes as well.

Each slot 42 is adjacent to at least one of the strata 40. In linearembodiments, the slots 42 may be grouped as internal full slots 42 a andexternal half slots 42 b. The internal slots 42 a are disposed betweentwo strata 40. The external half slots 42 b are adjacent to one strata40. Typically the external half slots 42 b are the first and the lastslots 42 on a mover 32. The distance across a slot 42 between two strata40 is a slot width Ws. In one embodiment, the slot width Ws may be aboutthe same as the tooth width W. In other embodiments, the slot width Wsmay be different than the tooth width W. Two of the external half slots42 b are equivalent to one full slot 42 a. The mover slot pitch Sp isthe distance between the midpoint of a first slot 42 and the midpoint ofthe next adjacent slot 42.

In one embodiment, the plurality of slots 42 is a multiple of the numberof phases of the linear propulsion machine or linear motor 48 thatcomprises at least one mover 32 and at least one stator 30. Morespecifically, the quantity of slots 42 is a multiple of the number ofphases P of the linear motor 48 in order to achieve a balanced windingand may be defined by the equation: quantity of slots=k*P where k is aninteger. For example, in the embodiment of FIG. 3, the linear motor is athree-phase machine. The value of P is three (3), the value of k isthree (3) and the resulting number of slots is equivalent to nine (9)full slots (eight full slots 42 a plus two half-slots 42 b).

Each wire coil 44 is disposed in at least one slot 42. Each coil 44 iswound around, or encircles, the combination of magnet layer 46 and theat least two strata 40 that sandwich the magnet layer 46. As can be seenin FIG. 3, two separate coils 40 are wound through, or disposed in, eachinternal slot 42 a.

The coils 42 may be operably connected to a source of electrical current(not shown). The source may provide multi-phase current as is known inthe art. For example, the linear motor illustrated in FIG. 3 is athree-phase machine that can receive the three alternating currents A,B, C of a three-phase electrical source. In such a three-phase system,three groups of coils 42 (A, B, C) each carry one of the threealternating currents of the same frequency which reach their peak valuesat one third of a cycle from each other. As illustrated in FIG. 3, thecoils 42A and 42A′ carry the A phase, the coils 42B and 42B′ carry the Bphase, and the coils 42C and 42C′ carry the C phase. Current directioninto the page is indicated by A′, B′ and C′. Current direction out ofthe page is indicated by A, B, C.

Each coil 44 may be made of a conductive material such as copper,aluminum, a combination of the two, or the like. Each coil 44 has anactivated state and a deactivated state. When activated, current isflowing in the coil 44. Each coil 44 disposed, in relation to the magnetlayer 46, perpendicular to the direction of magnetic flux of the magnetlayer 46 around which the coil 44 is wound. This orientation ensuresthat the current in the coil 44 is also perpendicular to the magneticflux.

Each magnet layer 46 is sandwiched between two of the strata 40 anddisposed inside one of the plurality of coils 44. Each magnet layer 46may be a permanent magnet or an electromagnet. The plurality of magnetlayers 46 are mounted on the mover 32 to have reversed polarities withconsecutive magnet layers 46 in a longitudinal direction along the mover32.

In operation, the interaction of the activated coils 44 of the mover 32with the stator 30 produces a thrust on the mover 32 attached to the car14 and propels the car 14 along the stator 30. While, the combination ofstator 30 with the mover 32 is described in conjunction with use as amotor 48, it may also be used as a generator during regeneration.

Turning now to FIG. 4, therein is illustrated another embodiment of amotor 48. Elements of FIG. 4 that correspond to elements in FIG. 3 arelabeled with the same reference numerals where practicable. In theembodiment of FIG. 4 the elevator system 10 includes a first stator 30a, a second stator 30 b and a mover 32 disposed between the first andsecond stators 30 a, 30 b. The stators 30 a, 30 b are similar to thatdiscussed with reference to the embodiment of FIG. 3 except that, inorder to facilitate flow of flux between the mover 32 and each of thestators 30 a, 30 b, each of the strata 40 are not L-shaped as they werein the embodiment illustrated in FIG. 3. The teeth 34 a of the firststator 30 a and the mover 32 define a first gap 38 a, and the teeth 34 bof the second stator 30 b and the mover 32 define another gap 38 b. Asin the previous embodiment illustrated in FIG. 3, each gap 38 a, 38 bmay be an air gap. Further, each of the teeth 34 a, 34 b of the eachstator 30 a, 30 b may be a magnetic pole Ma, Mb. To achieve betterperformance, the teeth 34 a of the first stator 30 a may be offset(vertically) from the teeth 34 b of the second stator 30 b. In oneembodiment, the offset may be in the range of greater than zero to aboutone stator channel pitch Cp. The channel pitch Cp is defined as thedistance from the midpoint of a first channel 35 to the mid-point of asecond adjacent channel 35. The offset is beneficial to the productionof useful force/torque. Maximum thrust force may be generated when eachof the teeth of one stator is offset from the teeth of the otheropposing stator by half of a stator channel pitch Cp.

Turning to FIG. 5, therein is schematically illustrated the lines ofmagnetic flux of the exemplary embodiment illustrated in FIG. 4 when thecoils are excited by a current load. As can been seen the lines ofmagnetic flux 50 flow from one of the poles of the magnet layer 46, inthis embodiment a permanent magnetic layer, to the stator teeth 34 andback to the magnet layer 46. In FIG. 5, the coils have been removed fromthe illustration so as not to obscure the magnetic lines of flux 50 inthe illustration.

Turning now to FIG. 6, therein is illustrated an embodiment of thelinear motor 48 for use in the elevator system 10. Elements of FIG. 6that correspond to elements in FIG. 3 are labeled with the samereference numerals where practicable. In the embodiment of FIG. 6, thelinear motor 48 of the elevator system 10 includes a stator 30 disposedbetween two movers 32, namely a first mover 32 a and a second mover 32b.

Both of the movers 32 a, 32 b are mounted to a car 14. The first mover32 a and the teeth 34 of the stator 30 define a first gap 38 a as doesthe second mover 32 b and the teeth 34 of the stator 30. Thisarrangement includes double the magnets of the embodiment shown in FIG.3 and thus provides a higher power density and force on the movers 32 a,32 b relative to the other embodiment.

Turning to FIG. 7, therein is schematically illustrated the lines ofmagnetic flux of the exemplary embodiment illustrated in FIG. 6 when thecoils are excited by a current load. As can been seen the lines ofmagnetic flux 50 that flow from the poles of the magnet layers 46, inthis embodiment a permanent magnetic layer, to the stator teeth 34 andback to the magnet layers 46 are combined for the two movers 32 a, 32 b,which generates a greater thrust or force on the movers 32 a, 32 b thanin embodiments having only one mover 32. In FIG. 7, the coils have beenremoved from the illustration so as not to obscure the magnetic lines offlux 50 in the illustration.

Turning now to FIG. 8, therein is illustrated an alternative embodimentin which the elevator system 10 includes two of the linear motors ofFIG. 6. More specifically, the elevator system 10 of FIG. 8 includesfirst, second, third and fourth movers 32 a, 32 b, 32 c, 32 d mounted toa car 14. Similar to the embodiment of FIG. 6, the stator 30 is disposedbetween the first and second movers 32 a, 32 b. In FIG. 8, the stator 30is also disposed between the third and fourth movers 32 c, 32 d.Elements of FIG. 8 that correspond to elements in FIG. 3 are labeledwith the same reference numerals where practicable.

Each of the third and fourth movers 32 c, 32 d is offset a distance Dfrom the first and second movers 32 a, 32 b. This offset reduces thethrust force ripple to provide a better quality ride in the car 14 forpassengers. Thrust force ripple may occur due to variation in stator 30permeance experienced by the movers 32 a, 32 b, 32 c, 32 d as theytraverse the stator 30. Reduction in thrust force ripple can be achievedby adjusting the position of the movers 32 a, 32 b of the first linearmotor 48 a relative to the movers 32 c, 32 d of the second linear motor48 b so that the instantaneous thrust force ripple generated by each iscancelled while the average thrust force is maintained constant. Thisreduces vibrations and improves ride quality. The distance D may be inthe range of greater than zero to about one per unit stator channelpitch Cp.

FIG. 9 illustrates the average thrust force 52 and percentage thrustforce ripple 54 as a function of offset between the two linear motors 48a, 48 b of FIG. 8. The offset has been unitized in terms of statorchannel pitch. It can be seen that there are three different offsetdistances, in this exemplary embodiment, that result in thrust forceripple being reduced from about 48% to about 12%. This is achieved bygenerating an instantaneous thrust force of linear motor 48 b (FIG. 8)that is out of phase to that of linear motor 48 a. In the exemplaryembodiment illustrated in FIG. 9, the ranges of per unit stator channelpitch Cp that provided lower thrust force ripple were as follows: about0.14 to about 0.17 per unit stator channel pitch Cp; about 0.47 to about0.53 per unit stator channel pitch Cp; and about 0.80 to about 0.86 perunit stator channel pitch Cp.

FIG. 10 illustrates the thrust force as a function of linear motoroffset. Line 56 illustrates the machine force per unit for linearmachine 48 a, line 58 illustrates the machine force per unit for linearmachine 48 b, line 60 illustrates the total force generated by the twolinear motors 48 a, 48 b without offset, and line 62 illustrates thetotal force generated by the two linear motors with offset.

FIG. 11 illustrates a variation in which the teeth 34 of the stator 30may be angled. Although shown with regard to the embodiment of FIG. 3,this variation is applicable to each of the aforementioned embodimentsin FIGS. 3-4, 6 and 8. The term “angled” as used herein means rotated anangle from a plane H perpendicular to the direction of thrust on themover 32 generated by the interaction of the mover 32 with the stator30. The angle for the stator 30 teeth 34 is the angle a and may be inthe range of about −60° to about 60° from the plane H perpendicular tothe direction of thrust on the mover 32 generated by the interaction ofthe mover 32 with the stator 30.

FIG. 12 illustrates a variation in which the magnet layers 46 of themover 32 may be angled. Although shown with regard to the embodiment ofFIG. 3, this variation is applicable to each of the aforementionedembodiments in FIGS. 3-4, 6 and 8. The angle for the mover 32 magnetlayer 46 is the angle 8 and may be in the range of about −60° to about60° from the plane H perpendicular to the direction of thrust on themover 32 generated by the interaction of the mover 32 with the stator30.

FIG. 13 illustrates in an enlarged schematic a variation of theexemplary magnet layer 46. This variation is applicable to each of theaforementioned embodiments in FIGS. 3-4, 6, 8, 11 and 12 and aids inreducing magnet losses and achieving higher operating efficiencies. InFIG. 13, each magnet layer 46 may be comprised of one or more magnets.In the example shown in FIG. 13 the magnet layer is comprised of threemagnets, a first magnet 66 a, a second magnet 66 b and a third magnet 66c. The magnet 66 a disposed closest to the stator teeth 34 may be madeof a bonded magnet with high resistivity properties. The second and thethird magnets 66 b, 66 c may be sintered magnets. In another embodiment,each magnet layer 46 may be comprised of a plurality of magnetsincluding a group of sintered magnets and a group of bonded magnets.Each magnet in the sintered group is a sintered magnet, and each magnetin the bonded group is disposed between the sintered group and thestator teeth 34 and is a bonded magnet with high resistivity properties.

FIG. 14 illustrates, in an enlarged schematic, a variation of theexemplary stator. This variation is applicable to each of theaforementioned embodiments in FIGS. 3-4, 6, 8, 11, 12 and 13. In FIG.14, each magnet layer 46 may be trapezoidal shaped. The trapezoidalshape helps reduce magnetic saturation and allows the linear propulsionmachine to operate at higher force densities.

FIGS. 15-16 illustrate variations in which a plurality of surfaces 70 ofthe strata 40 (of the mover 32) and/or a plurality of surfaces 72 of thestator 30 may be skewed. The term “skewed” as used herein means that theapplicable surfaces 70, 72 taper from a plane perpendicular to thedirection of thrust on the mover 32 generated by the interaction of themover 32 with the stator 30. The variations illustrated in FIGS. 15-16may be applicable to each of the aforementioned embodiments in FIGS.3-4, 6, 8, and 11-14, and with each other.

FIG. 15 is an enlarged view showing a portion of an exemplary mover 32.FIG. 15 illustrates a variation in which one or more surfaces 70 of eachof the strata 40 of the mover 32 may be skewed. In FIG. 15, the wirecoils 44 and permanent magnet layers 46 have been removed in order tobetter show the skewing of the strata 40. In the exemplary embodiment ofFIG. 15, each strata 40 includes an outer side surface 70 a, an innerside surface 70 b; a left side surface 70 c and right side surfaces 70d; the outer side surface 70 a of each strata 40 (that is adjacent tothe permanent magnet layer 46) is skewed and the inner side surface 70 b(that is adjacent to the wire coils 44) is skewed. In this particularembodiment, left and right sides surfaces 70 c, 70 d are not skewed. Inan embodiment in which the strata 40 are skewed as described above, thepermanent magnet layers 46 and wire coils 44 of the mover 32 may also beskewed in order to accommodate the strata 40 geometry.

FIG. 16 is an enlarged view showing a portion of an exemplary stator 30.FIG. 16 illustrates a variation of the stator 30 in which one or moresurfaces 72 of the stator may be skewed. In the exemplary embodiment ofFIG. 16, each tooth 34 has an upper and lower side surface 72 a, 72 b.It can be seen that the lower side surface 72 b of each tooth 34 isskewed. Although not visible in the illustration, the opposing upperside surface 72 a of each tooth is also skewed in this embodiment.

INDUSTRIAL APPLICABILITY

In light of the foregoing, it can be seen that the present disclosuresets forth a linear propulsion system. In one exemplary embodiment thelinear propulsion system is an elevator system utilizing one or morelinear motors per car. Such elevator systems may be most appropriate forpropulsion of non-counterweighted or ropeless elevator cars.

In the embodiments disclosed herein, the stator is free of activeelements and is mechanically strong, rigid and simplified. The activeelements, the magnetic layers and the coils of wire, are disposed on themover instead of the stationary stator positioned in the hoistway.Because the magnets and coils of wire do not line the entire statortrack, fewer are utilized overall. This results in a more cost efficientsystem without sacrificing thrust force. In addition, the angling ofeither the teeth of the stator or the magnet layer results in improvedefficiency and skewing results in reduced thrust force ripple.

Furthermore, in embodiments in which a plurality of linear motors areutilized for each car, the linear motors may be so positioned on the carto reduce thrust force ripple.

While only certain embodiments have been set forth, alternatives andmodifications will be apparent from the above description to thoseskilled in the art. These and other alternatives are consideredequivalents and within the spirit and scope of this disclosure.

What is claimed is:
 1. A linear propulsion machine comprising: a firststator, the stator including a plurality of teeth; and a first moveradjacent to the first stator and moveable in a linear direction alongthe first stator, the mover including: a plurality of spaced apartferromagnetic strata; a plurality of slots, each of the slots adjacentto at least one of the strata; a plurality of wire coils, each coildisposed in at least one slot, the coils having an activated state and adeactivated state; and a plurality of magnet layers, each magnet layersandwiched between two of the strata and disposed inside one of theplurality of coils, wherein each coil is disposed substantiallyperpendicularly to the direction of magnetic flux of the permanentmagnet layer around which the coil is wound, wherein the teeth or thepermanent magnet layer is disposed at an angle from a planesubstantially perpendicular to the direction of thrust on the firstmover generated by the interaction of the first mover with the firststator.
 2. The linear propulsion machine of claim 1, wherein theplurality of slots is a multiple of a number of phases of the linearpropulsion machine.
 3. The linear propulsion machine of claim 1, whereineach of the plurality of teeth includes a skewed side surface.
 4. Thelinear propulsion machine of claim 1, in which each of the plurality ofteeth has a tooth width and a distance across the slot between twostrata is a slot width, wherein the slot width is about the same as thetooth width.
 5. The linear propulsion machine of claim 1, wherein eachof the strata includes a skewed strata side surface.
 6. The linearpropulsion machine of claim 1, further including a second stator,wherein the first mover is disposed between the first and secondstators.
 7. The linear propulsion machine of claim 1, further includinga second mover moveable in a linear direction along the first stator,wherein the first stator is disposed between the first and secondmovers.
 8. The linear propulsion machine of claim 7, wherein the magnetlayers of each of the first and second movers are angled in relation tothe first stator.
 9. The linear propulsion machine of claim 7, furtherincluding a third and fourth mover moveable in a linear direction alongthe first stator, wherein the first stator is disposed between the thirdand forth movers and the third and fourth movers are offset from thefirst and second movers.